1.
Scope of Work
This method statement explains
the method for installation of HVAC control systems. HVAC Control System
includes
1.1 Cable Tray and Conduiting.
1.2 Field Instrument Devices with Idendification
Tag.
1.3 HVAC control panels-DDC
1.4 Control cables & Termination.
2.
Reference Documents
2.1 Approved
Drawings
2.2 Catalogues &
Vendor Documents.
2.3 Standards
& Specification for Control System.
2.4 Material Submittals for HVAC Control System
3.
Definition and Abbreviation
3.1 SAES Saudi Aramco Engineering Standards
3.2 SATIP Saudi Aramco Technical Inspection
Procedure
3.3 SAIC Saudi Aramco Inspection Checklist
3.4 NEC National Electrical Code
3.5 IEC International Electro-Technical
Commission
3.6 RFI Request for Inspection
3.7 MRR Material Receiving Report
3.8 ITP Inspection and Test Plan
3.9 COMPANY LUBEREF or its Designated
Representative
3.10 CONTRACTOR SAMSUNG
Engineering Const. Ltd
3.11 SUBCONTRACTOR Any
individual or Corporation under contract to the
CONTRACTOR who perform the entire and/or some portion of the work or
services on a project which the CONTRACTOR has agreed upon.
4.
Responsibilities...
4.1 Electrical
/ Instrument Engineer
·
He shall be overall responsible for the complete activity, including,
but not limited to:
a.
Assigning workman crew.
b.
Sequence of activities to be carried out in the work as per the method
of stating.
c.
Stage inspection & Surveillance.
d.
Notification to the client/consultant engineer/QC for inspection and
daily work activities.
e.
Provide day to day guidance and delegate works as necessary.
f.
Ensure that the equipment and tools required for carrying out the
activities are available on site and
used in a safe manner.
g.
Produce all necessary records for the confirmation of work completed and
pass to QC inspector as required.
4.2 Electrical / Instrumentation
Supervisor
·
He shall be overall responsible for the activity, including, but not
limited to:
a. Assigning workman
crew.
b. Sequence of
activities to be carried out in the work.
c. Ensure that the
quality levels for the works are maintained.
d. Ensure that the
equipment and tools required for carrying out the activities are available on site and used in a safe
manner.
4.3 QA / QC Inspector
a. Verification of
material approval and vendor certification..
b. Carry out day to day
surveillance so as to ensure that the work is carried out as per the standards.
c. Maintain records of
quality control check lists / reports for the site work inspection.
5. Control
Measures..
5.1 Quality Control
a.
Ensure availability of the latest released for construction drawings and Specifications.
b.
Ensure that the tools / equipments used for testing purpose are calibrated and certificates
available.
5.2. Safety
a. All equipments and
accessories have been certified for their capacity and integrity.
b. Safety and risk
assessment shall be performed for every job or task which has the potential for
harm.
c. All personnel are issued
with Personnel Protective Equipment with FRC.
d. Provide Hand gloves
and educate workers for safe operation.
e. Provide safety harness
and educate workers to attend safety training who are working at height.
f. Always try to keep
the work area clean.
5.3 Material Receiving, Storage & Inspection
a. Upon receipt of the
material, it shall be inspected with respect to project specification, approved
construction drawings, data sheets and delivery note.
b. Visual inspection
shall be carried out to check the condition of the panels. Be sure to note and
report any damage on the MRR documents.
c. Care should be taken
while choosing a location for panel storage. It should be stored indoors on
adequate location, elevated off the ground, well-ventilated and dry surface. To
prevent damage to cable tray, never pull cable tray from truck trailer by
chaining to bottom rung and dragging out of the trailer.
d. Cable tray is made of
either corrosion-resistant metal, such as aluminum or stainless steel, or metal
with a corrosion-resistant finish with one of the following process:
i)
Hot-dip
galvanizing after fabrication
ii)
Hot-dip
mill galvanizing
iii)
Electro
deposited zinc
iv)
Other
coatings as appropriate for the application
e. Cable tray must be
protected or stored in a well ventilated, dry location. Small accessories shall be stored to prevent loss.
f. Cable tray shall be properly supported, elevated off the ground,
and stacked by width and type.
g. After
receipt and inspection, all instruments shall be clearly marked with tag number
and it shall be stored in an environmentally control building or outdoors with
protection against weather
elements, in accordance with the
manufacturer guidelines for instrument protection.
h. Electronic instruments
shall be stored
inside on the platforms
or blocks at least 150mm above
grade and covered with tarpaulins to protect them from the weather.
i. Any
document coming along with the instrument box shall be kept & documented by
Samsung.
j. Small accessories of panel should be stored to prevent loss.
6. Sequence of Activities...
6.1 Procedure (General)
a. Check approval of construction drawings.
b. Check the size and route of Cable conduit & Cable tray for control
cable pulling as per the approved construction drawing.
c. Install the supports of Cable conduit & Cable tray as per the
standard.
d. Check the Cable conduit & Cable tray ends are free from sharp edges.
e. Install the conduits and provide Locknuts & end bushings.
f. Provide junction box/pull box where necessary and as per standards.
g. Visual Inspection for Cable conduit & Cable tray installation.
h. Pull the cable and make sure that there is 70% free space available
inside conduits.
i.
Check for insulation resistance and continuity
of the cable after installation.
j.
Check the panels are free from damages.
k. Install the control panels in the correct location as per the approved
construction drawing.
l.
Visual Inspection for Panel Installation.
m. Check the conduit/cable entry (gland / connector) to the panels is as per
standards.
n. Provide end bushings with ground for conduit/gland entry to the panels.
o. Make sure that the panels are properly grounded.
p. Make sure that the field devices are installed in the correct location
and of the correct type.
q. Provide approved cable lugs of proper size for cable termination.
r. Check the terminated lugs are fastened enough.
s. Provide cable tags for cable identification.
t.
Visual inspection for panel termination.
u. The system is ready for function test & commissioning.
6.2 Installation
Procedure (Cable Support Installation)
a)
In
order to install the cable tray supports, first find the required elevation
from the floor to the bottom of the cable tray and establish a level line as
per approved construction drawing.
b)
Bore
concrete for anchoring and hanger support. Ensures that the anchors are
properly fixed and aligned.
c)
For
wall and single strut cantilever bracket, secure the brackets to the structure
making sure they are level and aligned with each other.
d)
Welding
shall be done for supports as necessary.
e)
Fabricated
cable trays supports need to be retouched with appropriate paint after cutting,
drilling, or deburring or if the coating gets damaged.
6.3 Installation
Procedure (Cable Tray Installation)
a) After the supports
are in place, the installation of the cable tray can begin at any place that is
convenient. It is not necessary to start at one end of the run. It is ideal to
lay out the system so that splice joints fall between the support and the
quarter point of cable tray. This maximizes the rigidity of the cable tray.
b)
Install
cable tray ensuring that it is properly fixed to its supports. Where necessary
to cut the cable trays, the cutting line of the cable trays shall be through
continuous metal parts and not through the perforation. Burrs and sharp ends
shall be removed prior to the installation of tray section or accessories.
c)
Cable
tray shall be connected to adjacent lengths, tees, bends and fittings with
approved couplers and securely fastened by mushroom head steel roofing
bolts and nuts. Connection
shall be mechanically strong, so that there is no relative movement between
joints.
d)
Place
the next straight section across the next support, and attach it to the
previous section with a pair of splice plates and hardware. Splice plates shall
be placed on the outside of the
Cable tray, unless otherwise specified by the manufacturer, with the bolt heads
on the inside of the Cable
Tray.
e)
Holes
for splice plates must be drilled in field-cut Cable tray. A common method of
locating the hole positions is to use a splice plate as a template.
f)
Clearances
shall be maintained / observed during installation between Cable trays /
Supports and from any services. Identify cable tray separation of voltage and
service as per Construction drawing and Specification.
g)
For
floor and roof installation, cable tray shall not be laid directly on the floor
or roof. It shall be mounted far enough off the floor or roof to allow the
cables to exit through the bottom of the cable tray. If Unistrut is used for
this purpose, mount the strut directly to the floor or roof and attach the
cable tray to the Unistrut using hold-down clamps and/or guide clamps.
h)
Cable
trays that have a hot dip galvanized coating applied after fabrication need to
be retouched after cutting, drilling, or deburring or if the coating gets
damaged.
i)
After
completion of the work, inspection shall be carried out prior to cable pulling.
Examine cable paths to ensure all areas are free from debris that may interfere
with the cable installation.
j)
Cable
tray covers shall be provided and installed as a mechanical protection in outdoor
area prone to direct sunlight. Flange type covers shall be secured with banding,
one band per meter of cover length with a minimum of 3 bands per cover. If the cable
trays are installed indoor locations, the tray cover shall be installed on the
top layer only.
k)
Provide
identification / labels on cable tray and node marked. Identification made up a
stencil and spray paint.
l)
Mark-up
/ As Built drawings for any changes of routing of cable tray.
m)
Clean
the cable tray including the area where cable tray system is installed.
6.4 Installation
Procedure (Grounding and Bonding Installation)
a)
Grounding
works for the cable tray system shall be in accordance with Issued for
Construction (IFC) drawings (Erection details / Grounding system layout
drawings), SAES-J-902 and SAES-P-111 or as supplemented by this guideline.
b)
Metal
cable trays must be grounded and electrical continuous systems.
c)
If
the cable tray is to be used as an Equipment Ground Conductor (EGC), bonding
jumpers must be installed on both side rails at the locations illustrated
below:
Figure A
EXPANSION SPLICE PLATES
|
Figure B
HORIZONTAL ADJUSTABLE SPLICE PLATES
|
Figure C
DISCONTINUOUS SEGMENTS
|
Figure D
CABLE TRAY SECTIONS VERTICAL
ADJUSTABLE SPLICE PLATES
|
d)
Typical
installation of grounding bonding for cable tray is to drill holes inside rail
50 mm from each end of the splice plate so the jumper will span the
discontinuity. Do not use splice plate bolt locations to connect jumper to
cable tray.
e)
Place
screw head on inside of cable tray, put a jumper on outside of cable tray, add
flat washer,Locknut and tighten.
f)
Bare
cooper shall not be used as a bonding conductor at cable tray.
g)
When
a separate EGC cable is installed in or on cable tray, it may be bonded to the
cable tray with a grounding clamp. Ground clamp style includes bolted lug type
that requires drilling the cable tray side rail and clamp-on styles that work
like a beam clamp.
h)
Bonding
jumper is not required if the separate EGC is properly bonded to all cable
tray.
i)
Minimum
size of grounding conductor can be referred to NEC standard and/or as per
Construction drawing.
6.5
Cable Pulling Procedure
a)
Field
supervisor shall organize the cable-pulling plan, lifting method to be used (by
boom truck, crane or forklift), number of required persons and location of
cable drum.
b)
Cable
drum will generally be placed on drum jacks with an axle of sufficient size and
strength to allow the drum to turn freely with a minimum of friction.
c)
Communications
shall be established between the pulling end of the run and the drum end of the
run.
d)
Be
sure to have adequate personnel available at the drum end to aid in feeding the
cable, watching to prevent cables from being crossed and for drum braking if
necessary.
e)
Cables
may be pulled by hand with operatives placed at frequent intervals to support
the cables and avoid excessive tension. Where cables are not supported at
frequent intervals by operatives, then they must be supported by cable rollers
and placed at suitable intervals to avoid contact of cable sheath with abrasive
surfaces.
f)
The
cable shall be pulled by hand at a constant speed during the pull.
g)
Cable
pulling lubricant (pulling compound) shall be applied during cable pulling
inside conduits. Induct banks care shall be taken to protect the cables already
pulled by means of temporarily inserted half cut PVC pipes or by means of
rubber sheets placed above cables already pulled.
h)
Ensure
that the cables are installed at the correct level of ladder rack in accordance
with the cable pull-sheet.
i)
The
cable shall not be pulled bends excessively; Care shall be taken to avoid any
scratches on the cable sheath while pulling cables.
j)
Do
not allow the cables to drop in the cable tray as this may damage the cable
and/or the cable tray.
k)
Extra
care shall be taken when pulling cables to avoid loops. If a loop shall occur
under no circumstances, attempt be made to remove the loop by tensioning the
cable, the loop shall be removed by carefully coiling to the nearest end.
l)
Unwind
the cable from the drum to secure the required extra length to reach the panel
and coil it on the tarpaulin.
m)
When
the cable reaches end of the trench at the equipment location, allow two (2)
meters of extra length of cable fro dressing and termination requirements.
n)
Cutting
cables must be done with appropriate tools such as hydraulic shears, hand
shears, cable cutter or hacksaw (measure the required length before cutting).
o)
Immediately
after a cable has been laid and cut temporary protection cover shall be made on
the ends to avoid moisture absorption to the cable strands and temporary
identification label shall be made at each end, the identification shall be as
on the cable pull schedule. Final label or identification will have to be
installed after termination is completed.
p)
Each
cable shall be dressed to provide for the right installation along its entire
length. Once, all cables have been laid on a route level; dress the cables,
removing all temporary tie wraps and securing with permanent tie wraps/clamps
on all vertical cable risers.
q)
Mark-up
/ as-Built drawings for any changes made. Clean the area after completing cable
pulling, cable tagging were installed.
6.6 Field mounted instruments
/ Devices
a) Prior
to Instruments / Device installation check the elevation is as per the standard
and approved construction drawings.
b) If
installed with supports make sure that the supports are strong enough and bolts
are fastened.
c) Where
possible the instrument shall be installed in 1.4m from grade level.
d) All
indicating instruments should be installed at visible height.
e) Where
required, the instruments / Devices shall be provided with sunshade as per the
approved construction drawings.
6.7
Control Panel Installation
a)
Control
panel installation shall be done based on project specification, plan drawings,
and related vendor document of the control system.
b)
Prior
to panel installation it shall be ensured that inside the access floor are
clean and free from debris that may interfere with the panel installation.
c)
Rubber
plate (PAD) will be placed between support and panel base.
d)
The
panel shall be correct mounted horizontally, vertically using the specified
liners.
e)
Upper
and front side of the panel shall be correctly mounted in place.
f)
Once
the panel is aligned properly Stud bolt & Nut will be tightened properly.
g)
After
completion of the work, the panels shall be cleaned and covered with suitable
protective materials.
h)
Any
energization / preservation if required, shall be carried out on vendor /
client presence and recommendation.
i)
Other
consoles & accessories shall be installed as per the approved layout
drawing.
6.8 Cable Gland
Installation
a)
Cable
gland installation shall be in accordance with the recommendations of cable
gland manufacturer or as per following typical installation guideline.
b)
Fit
rubber shroud over the cable outer sheath, if applicable.
c)
Prepare
the cable by stripping back the outer sheath and armor to suit the equipment
geometry. Expose the armor by stripping back the outer shear further using the
Detachable cone or Reversible armor cone length as a cable-strip equivalent
length. If applicable, remove any tapes or wrappings to expose the cable inner
sheath.
d)
Secure
the entry component into the equipment.
e)
Locate
the detachable armor cone into the recess of the entry component.
f)
Pass
cable through entry component evenly spacing the armor around the cone.
g)
Whilst
continuing to push the cable forward to maintain the armor in contact with the
cone tighten the body of sub-assembly onto the entry component.
h)
Ensure
the two components make “metal to metal” contact. Tighten the outer seal nut
until either:
i)
The
outer seal nut makes metal to metal contact with the gland body,
ii)
The
outer seal nut has clearly engaged the cable and cannot be further tightened
without the use of excessive force by the installer.
i)
This
completes the procedure for cable gland installation.
6.9 Cable
Termination Procedure
a)
Typical
termination works shall be in accordance with the recommendations of cable
manufacturer’s instructions or as per following typical termination guideline.
b)
The
cable has to be properly dressed inside the junction box, cabinets, marshalling
panel, instruments etc.
c)
The
lugs/ferrules used shall be of proper size and type. Ring type lugs shall be
used in the places where 100% break free termination is required, such as
Solenoid valves, Instrument installed in vibrating area, etc. In another place
depending on the type of terminal -bootless or pin type lugs shall be used.
d)
The
lugs shall be insulated type only, not be used for compensating cable and
single stranded cables.
e)
Crimping
shall be done with the proper crimping tool. Use of cutting pliers shall be
avoided. Ensure the terminal lugs are properly crimped with the right crimping
tool.
f)
Individual
conductors shall be terminated on terminal strips and identified with a tubular
wire marker installed on a terminal, cabinets marshalling panel, and junction
boxes. When heat shrinkable tubes are used, they shall be heat shrink and shall
be loose enough to replace easily, if necessary.
g)
Terminate
the core corresponding terminal blocks properly and check the tightness.
h)
Shielded
cable shall be grounded at one point only, typically at the marshalling cabinet
of the control room or process interface building (PIB).
i)
Ensure
that the wire loops are kept neatly bed with ties.
j)
Ensure
that all cables are clamped inside the Trunking and tie wrapped on instrument
tray with approval fixing material.
k)
Fix
the cable identification on a tag on the cable near to the gland using approved
straps.
l)
Ensure
that the cover of the equipments fixed after termination.
m)
This completes the procedure for cable
termination works.
6.10 Cable
Test Procedure..
6.11.1
Cable continuity test :-
a) Connect the free Megger test probes to
any two conductors required to be tested.
b)
With all the appliance connected
or the two ends of the conductors shorted and all Switches switched ON the
reading shown on the Megger should be zero. If the reading shows infinity then
there is an open circuit. The fault should be traced and rectified.
For cables, the extreme ends of any two phases
are shorted and when the test is conducted the reading should be zero if the
meter reads infinity or some value of mega ohms then there is a fault in the
cable and it should be rectified. The same procedure shall be repeated for
another 3 conductors of the cable.
6.11.2 Cable
Insulation Resistant Test.
a) For wires the circuit is tested, Megger range
should be 500V.
b) Between phase and
neutral.
c) Between phase to earth
d) Between neutral to earth
e) With the other ends
of the circuit conductor open the value should be infinity for all the tests.
If the value is zero, there is a short circuit or the insulation of the wire is
damaged and the wire is changed accordingly.
6.12 Pre-Commissioning & Commissioning,Start-Up
of HVAC Control Systems.
a) Close all punch list before pre-commissioning
b) Prior to pre commissioning check for
all Installation inspections as per ITP.
c) Prior to commissioning check for all Testing inspections as per ITP.
d) The Vendor only can do the pre-commissioning ,commissioning and Start Up activities.
e) Down load the Software program
for DDC Control Devices.
f) Manually check the UPS Power, Relays, Damper Actuator, Air Flow
devices,Pressure Transmitters through Panel.
g) After confirmation, check the whole system operate by manual mode.
h) After observation change over
from Manual mode to auto mode.
i)
The site acceptance test (SAT) Shall be
conducted by Vedor with the Contractor
and Clint representative Approval.
j)
The Vendor shall give the operator training to
Contractor and client representatives.
k) Operation and Maintenance shall be Monitored by HVAC Engineer until
handover to client.
l)
Record
all Data and submit to the client with Handover Documents.
7. Attachment
JSA (Job Safety Analysis)
SATIP-P-104-08 (HVAC Equipment)
SATIP-J-902-01 (metallic Instrumentation and control
cables.)
SATIP-P-104-03 (cable Tray)
SATIP-P-104-05 (A/G Conduit)
SATIP-P-104-07 (B/G Conduit))
SATIP-P-111-01 (Grounding & Bonding as applicable.)
SATR-P-3203 (cable continuity and
Insulation test.)
SATR-P-3205 (Power cable
termination Torque test)
SATR-P-3406 (cable continuity and Insulation
test.)
